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FINAL REPORT
Distribution: Attention:
TTI Testing Ltd (author, file)
MAIB
ALP Forward wire rope failure - Final Report
Summary
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ALP Forward wire rope failure - Final Report
Tensile breaking load tests were undertaken on whole rope samples from
the drum, tug and bridle sections. The results of these tests showed that
the strength of the drum sample was down by about 7% on the originally
measured breaking strength, whilst the tug and bridle samples were both
over 20% down on as new.
The nature and distribution of the wire failures in the breaking load
samples was very similar to the main failure (tug side sample). The outer
strand outer wires had predominantly failed in shear, whilst the outer
strand inner wires had failed in classic cup and cone type fractures. (The rig
side sample main failure was not inspected as it had suffered extensive
abrasion damage dragging along the seabed post failure.)
A consideration of the fatigue performance of the six strand rope indicated
that during the storm the wire rope would have accumulated fatigue
damage which would contribute to degradation.
Analysis of catenary behaviour indicated that under high tensions the wire
rope would be reliant on elastic stretch to accommodate any sudden
displacement caused by waves, and that very high tensions could easily be
produced by relatively small displacements.
It is concluded that the wire rope was weakened by accumulated damage
during the storm and ultimately failed by tensile overload in its weakened
state.
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ALP Forward wire rope failure - Final Report
Contents
Glossary .............................................................................................................................. v
1 Introduction ................................................................................................................ 1
2 Main tow wire rope..................................................................................................... 2
3 The towing arrangement and sample location ............................................................ 4
4 Delivery of samples ..................................................................................................... 7
4.1 Delivery of the drum sample ....................................................................................... 7
4.2 Delivery of the tug side and rig side samples .............................................................. 8
5 Initial inspection of samples ...................................................................................... 11
5.1 Initial inspection of drum sample .............................................................................. 11
5.2 Initial inspection of tug side sample .......................................................................... 12
5.3 Initial inspection of rig side sample ........................................................................... 15
6 Initial cutting schedule .............................................................................................. 18
6.1 Cutting schedule for drum sample ............................................................................ 18
6.2 Cutting schedule for tug side sample ........................................................................ 18
6.3 Cutting schedule for rig side sample ......................................................................... 18
7 Delivery of bridle sample........................................................................................... 20
8 Initial inspection of additional sample....................................................................... 21
8.1 Initial inspection of bridle sample ............................................................................. 21
8.2 Proposed cutting schedule for bridle sample............................................................ 22
9 Wire rope breaking strength measurement............................................................... 23
9.1 Test equipment.......................................................................................................... 23
9.2 Results of the breaking load tests ............................................................................. 25
10 Strip down inspection of 1 m samples ....................................................................... 31
10.1 Strip down inspection of Drum Sample ................................................................. 31
10.2 Strip down inspection of the tug side sample ....................................................... 40
10.3 Strip down inspection of the bridle sample........................................................... 48
10.4 Measurements made on strip down samples ....................................................... 57
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ALP Forward wire rope failure - Final Report
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ALP Forward wire rope failure - Final Report
Glossary
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ALP Forward wire rope failure - Final Report
1 Introduction
TTI Testing (TTI) has been contracted by the Marine Accident Investigation Branch (MAIB)
for assistance in determining the cause of a wire rope failure (MAIB Reference number
4/3/144). The wire rope was being used as the towing wire on ALP Forward to tow the
Transocean Winner between Norway and Malta when it parted in heavy weather on 8th
August 2016. The platform Transocean Winner subsequently ran aground at the Isle of
Lewis.
The MAIB seeks to understand why the wire rope failed and why it failed where it did.
Specifically:
• The condition of the wire rope where it failed and at other selected points
• The implications of its condition on serviceability at the time of failure
• The mechanism of the wire rope’s failure
• The load on the wire rope when it failed
• The load the wire rope would have failed at had it been new
This document presents background information relevant to the study, and describes the
initial inspection and testing of the sections of wire rope which were sent to TTI Testing,
Wallingford. Results of the tests are presented along with a discussion of the results to
address the questions raised above.
The examination of the pick-up rope and messenger line is covered in a separate report.
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ALP Forward wire rope failure - Final Report
Table 2.2 presents data from the individual wire tests for the wires in the main load bearing
strands of the rope.
Table 2.2: Average wire properties for the main load bearing outer strand wires (from Usha Martin
Inspection Certificate - See Appendix A).
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ALP Forward wire rope failure - Final Report
Figure 3.2: Schematic diagram of the bridle arrangement connecting Transocean Winner to ALP
Forward.
Figure 3.3: View on failure of 77 mm wire rope (tug side) (Photograph supplied by MAIB).
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ALP Forward wire rope failure - Final Report
Figure 3.4: Tug side sample taken for inspection: 20 m from the failure towards the tug ALP Forward
(Photograph supplied by MAIB).
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ALP Forward wire rope failure - Final Report
4 Delivery of samples
Figure 4.2: Drum sample as received at TTI Testing with crate lid fully removed.
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ALP Forward wire rope failure - Final Report
Figure 4.3: Container with tug side and rig side samples as received at TTI Testing.
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ALP Forward wire rope failure - Final Report
Figure 4.4: Container opened to show tug side (top) and rig side (bottom, wrapped) as received.
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ALP Forward wire rope failure - Final Report
Drum sample
Figure 4.6: Samples laid out in TTI Testing laboratory for initial inspection.
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ALP Forward wire rope failure - Final Report
Figure 5.2: Area of crushing damage found on the drum sample (mid-length).
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ALP Forward wire rope failure - Final Report
It is immediately noted that the lubricant between the strands is missing, the protective
galvanising seems low or lost, and the wires (the outside of the wire rope) are covered in
what appears to be superficial corrosion. Wire breaks were noted distributed along the 10 m
length, both along and around the wire rope circumference. In all 40 visible breaks were
counted (there may well have been more), all of which initiated at the inter-strand contact
region of the wire rope and appeared to be shear type in nature. Beyond 10 m from the cut
end there were many more wire breaks.
A more detailed assessment of the condition of the tug side sample was made on the full
inspection of a 1 m sample, including mechanical tests on the wires.
Figure 5.7: Outer strand wire break (valley) measured at 1.4 m from cut end on tug side sample.
Figure 5.8: Two of six outer strand wire breaks measured at 2.0 m from cut end on tug side sample.
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ALP Forward wire rope failure - Final Report
Figure 5.9: Two outer strand wire breaks measured at 5.6 m from cut end on tug side sample.
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ALP Forward wire rope failure - Final Report
Figure 5.10: General condition of the wire rope about 1.1 m from cut end of rig side sample.
Figure 5.11: Significant abrasion on the surface of the outer wires 2.0 m from cut end of rig side
sample.
Figure 5.12: Small pieces of stone noted trapped in the wire rope at 5.6 m from cut end of rig sample.
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ALP Forward wire rope failure - Final Report
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ALP Forward wire rope failure - Final Report
Figure 7.1: Bridle sample as received at TTI Testing complete with closed spelter socket.
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ALP Forward wire rope failure - Final Report
Figure 8.1: General condition of the bridle sample as received (7.1 m).
Figure 8.2: Group of at least eight wire breaks noted at 15.2 m on the bridle sample.
1
d is the nominal diameter of the rope and used as a characteristic length in the definition of discard criteria.
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ALP Forward wire rope failure - Final Report
Figure 8.3: Group of at least six wire breaks noted at 16.5 m on the bridle sample (the blue paint is
from the shipping container).
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ALP Forward wire rope failure - Final Report
Figure 9.1: Wire rope sample ready for testing in Mennens' 1,400 tonne tensile testing machine.
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ALP Forward wire rope failure - Final Report
Figure 9.2: Wire rope sample ready for testing with high speed filming equipment in place.
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ALP Forward wire rope failure - Final Report
Sample Breaking load [kN] Breaking load [%Fmin] Breaking load [%ABL]
Table 9.1: Results of the breaking strength measurement on the three wire rope samples.
Figures 9.3 - 9.5 show the drum sample following testing. It may be seen that the sample
failed clear of the terminations (Figures 9.3 and 9.4). Examination of the failure showed that
the majority of the wire failures were from tensile overload (as would be expected), with a
few shear type failures (given the helical nature of wire rope, this is also as expected).
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ALP Forward wire rope failure - Final Report
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ALP Forward wire rope failure - Final Report
Figure 9.6 shows the broken wires which fell out of the tug side sample when it was
terminated for testing. The wires are largely from the IWRC, which as the initial inspection
had shown was in fairly poor condition. In addition to the IWRC wires there were also some
outer strand outer layer wire breaks. The tug side sample failed mid-length (Figure 9.7).
Figure 9.6: Tug side sample - broken wires found in preparation of sample terminations. (Mostly
IWRC wires, but also some outer strand outer wires).
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ALP Forward wire rope failure - Final Report
Figures 9.8 and 9.9 show views on the groups of wire failures after testing of the tug side
sample. The inner layers of the main strands may b readily identified by their paler colour. It
can be seen that these wires failed with tensile cup and cone type failures. There were also
some shear failures (e.g. centre of Figure 9.9).
Figure 9.8: Tug side sample after testing, detailed view on wire failures.
Figure 9.9: Tug side sample after testing, detailed view on wire failures.
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ALP Forward wire rope failure - Final Report
As with the tug side sample, the core of the IWRC was found to be mostly in pieces when the
sample was prepared for testing (Figure 9.10). Additionally, there were also breaks in some
outer strand outer wires. As with the other samples, the bridle sample failed clear of the
terminations (Figure 9.11).
Figure 9.12 shows a group of shear wire breaks on one of the outer strands after testing. This
view is interesting as it shows clearly that there were three existing wire breaks in the
sample (corroded fracture surfaces), and two wires which were broken in the breaking load
test (fresh ends).
Figure 9.10: Broken wires found in preparation of Bridle sample terminations - mostly IWRC wires.
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ALP Forward wire rope failure - Final Report
Figure 9.12: Bridle sample after testing, detailed view on wire failures (old - rusty ends, new - shiny).
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ALP Forward wire rope failure - Final Report
The visual inspection of the samples was in line with the criteria set out in BS ISO 4309:2010
[5], and paid particular attention to corrosion, lubrication and mechanical damage.
Tests were performed on wires taken from positions throughout the wire rope cross section
to assess:
• Tensile strength;
• Torsions to failure;
• Reverse bends to failure; and,
• Residual zinc coat weight.
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ALP Forward wire rope failure - Final Report
Figure 10.2: Detailed view on the drum sample showing an area of corrosion. Note also the 'mud
deposits' and the good level of lubricant in the valleys.
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ALP Forward wire rope failure - Final Report
Figure 10.3: Drum sample with two outer strands removed to show the condition of the IWRC - the
lubricant level is very low. Note also the light corrosion on the outer strand (top right)
and the glassy bitumous lubricant in the valley positions (of the outer strands).
Figure 10.4 shows an outer strand after removal from the wire rope sample and partially
cleaned. Sections of lubricant have been left in place to highlight the difference in residual
galvanising levels between the section of strand normally on the outside of the wire rope,
and that facing towards the IWRC.
Figure 10.4: Drum sample outer strand partially cleaned to show the difference in residual
galvanising levels for sections on the inside and outside of the wire rope.
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ALP Forward wire rope failure - Final Report
The outer strand was then stripped down layer by layer to permit assessment of the internal
condition. Figures 10.5 - 10.7 show the second and third layers and core wire of the outer
strand. It may be seen that the inner layers and core of the outer strand are well lubricated
and have retained a good galvanising covering. No signs of degradation or wear were noted.
before cleaning
after cleaning
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
before cleaning
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ALP Forward wire rope failure - Final Report
after cleaning
Figure 10.7: Drum sample outer strand - third layer of wires and core wire (bottom).
Figure 10.8 shows the Manufacturers' marker tape which was found along the outside of the
IWRC. It confirms that the wire rope was manufactured by Usha Martin.
Figure 10.8: Manufacturers' identification tape found under the outer strands and on the IWRC
(Drum sample).
Figure 10.9 shows the drum sample with all the outer strands removed to show the IWRC. As
noted above, the lubricant level is low and what is there appears denatured and powdery.
An outer strand was removed to permit further examination. Figure 10.10 shows the core
strand after cleaning. It may be seen that the residual galvanising is patchy, but there is no
corrosion as such on the core strand. Dismantling the core strand shows that the lubricant
inside the strands is good and sticky, and that the residual zinc is a little patchy, but overall
good (Figure 10.11).
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ALP Forward wire rope failure - Final Report
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.11: Drum sample IWRC outer strand outer wires and core (bottom).
Figure 10.12 shows the IWRC core strand, which is similar in appearance to the IWRC, but
with more lubricant. On cleaning the outer surface of the core (Figure 10.13) it may be seen
that the residual galvanising is also patchy, but as with the outer strands, there is no
corrosion. Figure 10.14 shows the core after dismantling. It may be seen that the lubricant
level is good, and appears sticky in nature. The galvanising is a little patchy on the more
exposed surfaces.
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.14: Drum sample IWRC outer wires and core strand (bottom) cleaned.
Following inspection of the drum sample all six outer strands and the IWRC were stripped
down to check for wire breaks. None were found.
Wires were selected from various positions in the wire rope construction for the
measurement of the level of residual galvanising as well as tension, torsion and reverse
bending tests. The results of these tests will be presented later in this report.
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ALP Forward wire rope failure - Final Report
Figure 10.15: General condition of the tug side sample before cleaning.
Figure 10.16: Detailed view on single wire break noted in valley position on tug side sample.
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ALP Forward wire rope failure - Final Report
Figure 10.17 shows the tug side sample with two outer strands removed to reveal the IWRC.
The lubricant level was generally low (a single large patch was noted in one area (Figure
10.18)). As with the outer strands the residual galvanising was low, and there was corrosion
along the length of the core. Many wire breaks were noted in the IWRC outer strands
(Figures 10.17 - 10.20). The remaining outer strands were carefully removed to permit full
inspection of the core (Figure 10.18).
Figure 10.17: Tug side sample with two outer strands removed to reveal IWRC.
Figure 10.18: Tug side sample, general condition of IWRC. Five wires dropped out of the construction
as the outer strands were removed. Some areas of good level, good nature lubricant,
but on the whole the lubricant level was low and dry.
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ALP Forward wire rope failure - Final Report
Figure 10.21 shows the IWRC with two strands removed to show the core. The lubricant
level was much better than on the outer strands, but it was dry and flaky (Figure 10.22).
There did not appear to be much corrosion - the main feature noted was that the whole core
strand was broken through in several places. Once the outer strands were all removed it
could be seen that the core strand was broken through completely in five places (Figure
10.23), as well as having other wire breaks along its length.
Figure 10.21: Tug side sample, IWRC with two strands removed to show core. Core strand broken
through. Good level of lubricant.
Figure 10.22: Tug side sample, dry lubricant which dropped out of the wire rope.
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ALP Forward wire rope failure - Final Report
Figure 10.23: Tug side sample IWRC core - broken through in five places (6 pieces) over 1 m length.
Figures 10.24 and 10.25 show sections of the IWRC core and an outer strand after cleaning.
The IWRC core has some residual galvanising present, whilst the core strand has very little if
any. The corroded appearance noted above (Figure 10.21) has cleaned off. The wire failures
in both the strand and the core are the shear type, which are to be expected as the IWRC
experiences high transverse loads as it supports the main outer strands in the wire rope.
Figure 10.24: Tug side sample IWRC core strand after cleaning.
Figure 10.25: Tug side sample IWRC outer strand after cleaning.
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ALP Forward wire rope failure - Final Report
Figure 10.26 shows one of the main outer strands after cleaning. The wire break was located
in the valley position in the wire rope and was not detected until the strands were removed
to inspect the core. (In all four outer strand outer wire breaks were found in the 1 m sample
- only one of which was found before the wire rope was dismantled.) The break has initiated
at the wear patch on the surface of the wire, and failed in a mixture of shear and fatigue.
The 'beach' marks characteristic of fatigue may be seen on the right hand edge of the
fracture surface. It is also noted that there is very little residual galvanising left on the
surface of the strand.
Figure 10.26: Tug side sample main outer strand after cleaning.
Figure 10.27 shows an outer strand with four outer wires removed to reveal the second
layer. The contrast between the outer layer and second layer is quite marked: the level of
lubricant in the second layer is better, and although still low, the residual galvanising seems
better. Figure 10.28 shows the third layer of wires in the main strand before and after
cleaning. This 'far' into the strand the lubricant is much better both in level and nature and
the residual galvanising is also higher. Similarly the strand core wire had very good lubricant
and high residual galvanising levels. No corrosion was noted in any of the inner layers of the
outer strand inspected.
Following inspection of the sample, all outer strands were completely dismantled to check
for wire breaks. Apart from the four outer strand outer wire breaks, no internal wire breaks
were found. Indeed, the inside of the main strands were in generally good condition.
In contrast, as noted above, the IWRC was in very poor condition. The strands and core were
stripped down to count the wire breaks. In all there were 62 breaks in the outer strands and
59 in the IWRC core (total 121 wire breaks). Obviously there will be a loss of strength
associated with this level of degradation: the IWRC of a six strand wire rope typically carries
about 15% of the wire rope strength. What is more important is that a core with this level of
damage will not perform its main function which is to support the outer strands so that as it
bends they are free to slide and do not contact one another.
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.27: Tug side sample, main outer strand with four outer layer wires removed to expose the
second layer.
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.28: Tug side sample, main outer strand third layer of wires.
before cleaning
after cleaning
Figure 10.29: Tug side sample, main outer strand core wire.
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ALP Forward wire rope failure - Final Report
Figure 10.31: Detailed view on bridle sample - note no visible galvanising and a uniform covering of
corrosion causing roughening of the surface of the wires.
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ALP Forward wire rope failure - Final Report
Figures 10.32 and 10.33 show the bridle sample with two outer strands removed to expose
the IWRC. It may be seen that in some areas the lubricant was a quite a high level, if
somewhat denatured (Figure 10.32), whilst in other places along the core the level was low
(Figure 10.33).
Figure 10.32: Bridle sample with two outer strands removed - area of good lubrication on IWRC.
Figure 10.33: Bridle sample with two outer strands removed - area of low lubrication on IWRC.
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ALP Forward wire rope failure - Final Report
The outer strands were all removed to permit a detailed inspection of the core
(Figure 10.34). In general the lubricant level was higher than the tug side sample, making it
harder to assess for wire breaks (the sample was subsequently dismantled to allow a full
count to be made). It was also noted that there was sand on the surface of the IWRC. It is
not clear how this came to be on the wire rope, particularly in this position in the wire rope
construction, but with the lubricant missing from between the outer layer of strands it
would be possible for the sane to enter and become trapped in the wire rope.
Figure 10.34: Bridle sample IWRC. Note the lubricant level is reasonable if a little dry and
denatured, also the grains of sand.
Figure 10.35 shows the IWRC with three outer strands removed. The condition is very similar
to the tug side sample. The lubricant is at a reasonable level, if a little dry. As with the tug
side sample the core strand was broken through in several (in this case four) places
(Figure 10.36).
The wire failures in the core strand were typically shear type with the characteristic 45°
fracture surface (Figure 10.37). Figure 10.38 shows a dismantled section of core strand
before and after cleaning. It can be seen that the residual galvanising level on the wires is
very low, with only a few small patches observed, however the wires do not appear to be
corroded.
Figure 10.39 shows a IWRC strand after removal from the core and cleaning. The wire breaks
are typical of those found in the core strands. As with the tug side sample, all strands and
the core were stripped down to count the number of breaks. In the IWRC outer strands 69
wire breaks were counted and in the core 48 (total 117 breaks in 1 m of IWRC).
Figure 10.40 shows a section of dismantled IWRC strand before and after cleaning. As with
the core strand the residual galvanising is very low. Additionally, some areas of the wire
surface show a roughening from the start of corrosion.
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ALP Forward wire rope failure - Final Report
Figure 10.35: Bridle sample IWRC with three outer strands removed to show the core (all core
strand wires broken).
Figure 10.36: Bridle sample IWRC with three outer strands removed to show the core (all core
strand wires broken).
Figure 10.37: Bridle sample IWRC core showing typical shear type wire failures.
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.38: Bridle sample IWRC core, (some) outer wires and core wire (bottom).
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.40: Bridle sample IWRC strand, (some) outer wires and core wire (bottom).
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ALP Forward wire rope failure - Final Report
Figure 10.43 shows the second layer of the main strand before and after cleaning. The level
of lubricant is already much better than on the outer layer of wires, although somewhat
flaky and denatured. The cleaned wires show very little residual galvanising, and a slight
roughening of the surface indicates the onset of corrosion.
As with the tug side sample, further 'into' the strand the nature of the lubricant and level
was better, and the wires had retained more of their galvanic protection (Figures 10.44 and
10.45). No corrosion was noted in the third and core layers.
As with the IWRC, the outer strands were completely dismantled to check for broken wires.
A total of nine outer wire breaks were found. There were no wire breaks in the second, third
or core layers.
before cleaning
after cleaning
Figure 10.43: Bridle sample main strand second layer of wires.
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ALP Forward wire rope failure - Final Report
before cleaning
after cleaning
Figure 10.44: Bridle sample main strand third layer of wires.
before cleaning
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ALP Forward wire rope failure - Final Report
after cleaning
Figure 10.45: Bridle sample main strand (some of) the third layer of wires and core wire (bottom).
Table 10.1: Summary of measured lay-lengths and wire rope diameters on inspected sections.
Outer strand
Sample IWRC core IWRC strands
outer wires
Drum 0 0 0
Tug side 59 62 4
Bridle 48 69 9
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ALP Forward wire rope failure - Final Report
Figure 11.2: Tug side sample main failure, detailed view on one strand.
Figure 11.3: Composite SEM image of Wire 2 showing non tensile type failure.
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ALP Forward wire rope failure - Final Report
Figure 11.4: SEM image of tensile (cup and cone) failure of Wire 6 (outer strand second layer large
wire).
Figure 11.5: SEM image of shear failure of Wire 4 (outer strand outer wire).
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ALP Forward wire rope failure - Final Report
Attention was focussed on the outer strands and the outer wires of the outer strands, since
these represent the greatest percentage of load bearing area in the wire rope. Thus, for the
construction under consideration here it was decided to take:
• Three outer wires from each of four outer strands;
• One of each wire size from the second and third layers of three outer strands;
• One core wire from one outer strand;
• One wire of each size from the IWRC strand; and,
• One of wire of each size from the IWRC core.
Table 12.1 summarises the test samples which were extracted from the wire rope (one set of
each for the tension, torsion and bending tests).
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ALP Forward wire rope failure - Final Report
Third layer 1
Core 1
Third layer 1
Third layer 1
core 1
core 1
TOTAL 26
*Note the strand numbers are completely arbitrary, strands were selected at random
Table 12.1: Summary of the samples taken from the wire rope for tensile, torsion and bend testing.
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ALP Forward wire rope failure - Final Report
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OS1 CW IWRC CS CW
Figure 14.1: Typical appearance of wire failures in tensile tests on wires from the drum sample.
• The results of the torsion tests were a little more varied. The wires either passed by
some margin or failed rapidly (Figure 14.2). The torsion test is very sensitive to
surface condition, and it maybe that surface of the outer wires on some of the outer
strands was damaged leading to premature failure. The results of the tests on the
wires from the inside of the main strands were generally very consistent and good.
The tests undertaken on the IWRC wires were generally low. It is thought that the
reason for this may be the effort put into straightening the wires for testing. It is easy
to damage a wire despite taking great care in sample preparation. In contrast the
core wire which required no straightening performed well.
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ALP Forward wire rope failure - Final Report
Figure 14.2: Appearance of wire failures in torsion tests on wires from the drum sample. (Top
OS OW1 (7 turns/100dw), bottom OS CW (27 turns/100dw)).
• The reverse bend test (in addition to the torsion test) is means of assessing a wire's
ductility. The API 9A [1] does not have a minimum requirement for wires tested in
this manner, so the requirements of Standard 10264-2 [6] have been used. All the
wires in the reverse bend tests satisfied the minimum requirements of the Standard.
This would suggest that the wire material was ductile, but in the torsion tests the
surface had been damaged.
Figure 14.3: Typical appearance of wire failures in tensile tests on wires from the tug side sample.
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ALP Forward wire rope failure - Final Report
• The results of the torsion tests on the outer strand outer wires were all very low,
typically about 10% - 30% of the standard minimum requirement. The results of
these tests were significantly affected by the surface damage (wear) and corrosion
noted on the sample during the inspection (Figure 14.4). In contrast, all the wires on
the inside of the main strands performed well. These wires had not experienced
surface damage and were not corroded. The IWRC wires were very poor, but this is to
be expected given the state of the IWRC (two wire sizes could not be tested as a
sufficiently long sample could not be obtained!).
Figure 14.4: Appearance of wire failures in torsion tests on wires from the tug side sample. (Bottom
OS OW1 (3 turns/100dw), top OS CW (27 turns/100dw)).
• The reverse bend tests were a little better, with about half the outer strand outer
wires meeting the Standard minimum requirements. The outer strand inner wires
performed well and were at a similar level to the drum sample wires. The IWRC wires
performed better than in the torsion test, but the strand wires were still a little
down.
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ALP Forward wire rope failure - Final Report
Figure 14.5: Typical appearance of wire failures in tensile tests on wires from the bridle sample.
• The results of the torsion tests followed the familiar pattern - the outer strand outer
wires were low, typically 10% - 30% of the standard minimum requirement. The
outer strand inner layers of wires were comfortably in excess of the minimum, whilst
the IWRC wires (where available) performed poorly.
Figure 14.6: Appearance of wire failures in torsion tests on wires from the bridle sample. (Bottom
OS1 OW3 (3 turns/100dw), top OS1 CW (30 turns/100dw)).
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ALP Forward wire rope failure - Final Report
• The reverse bend tests were a little better, with half the outer strand outer wires
meeting the Standard minimum requirements. The outer strand inner wires
performed well and as with the tug side sample, were at a similar level to the drum
sample wires. The IWRC wires performed better than in the torsion test.
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ALP Forward wire rope failure - Final Report
Manufacturer's original
Class B
Figure 15.1: Measured average residual galvanising on wires from various positions in the wire rope construction on the drum sample.
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ALP Forward wire rope failure - Final Report
Manufacturer's original
Class B
Figure 15.2: Measured average residual galvanising on wires from various positions in the wire rope construction on the tug side sample.
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ALP Forward wire rope failure - Final Report
Manufacturer's original
Class B
Figure 15.3: Measured average residual galvanising on wires from various positions in the wire rope construction on the bridle sample.
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ALP Forward wire rope failure - Final Report
Figure 16.2: Showing for a range of loads how the catenary sag varies for a fixed line length (of
740 m) and weight per unit length (taken as 22.9 kg/m in water). Note only half the
catenary has been shown as it is assumed symmetrical about the y-axis.
Figure 16.3: Variation in horizontal load as a function of the span (wire rope length 740 m).
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ALP Forward wire rope failure - Final Report
ΔF
Young’s modulus E is defined as: E = A
Δ
Where: ΔF is the change in (wire rope force);
A is the nominal wire rope area;
ℓ is the initial length of the sample; and,
Δℓ is the change in length caused by the change in load (ΔF)
Re-arranging this equation gives:
ΔF
EA = ⋅
Δ
In this equation the term ΔF/Δℓ is the slope on the graph (shown by the blue line in Figure
16.5). The slope of the blue line in Figure 16.5 is 49.8 kN/mm and the length ℓ is 3190 mm,
which gives a value of EA of 159 MN.
This permits calculation of the change in force ΔF caused by the sudden wave imposed
movement Δℓ.
Hence the maximum load in the wire rope is the change in load + the initial load
It is again noted that this calculation is approximate, but does give an idea of the levels of
load which might have been experienced in the wire rope during the storm.
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Table 16.1: Approximate calculation of peak tensions experienced by the wire rope.
where:
N = Number of cycles
R = Ratio of tension range to rope MBL
M = 4.09 for six strand rope
K = 10(3.20 - 2.79Lm)
Lm = Ratio of mean load to rope MBL
Figure 16.7 shows the predicted number of cycles to failure for a rope loaded from zero to
peak tension (the load range) for varying load ranges. By way of example, it may be seen
that for a peak tension of 240 tonnes, the predicted number of cycles to failure would be
5,745 cycles. At a period of 14 s, failure would occur after about 22 hours.
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Figure 16.7: Mean cycles to failure as a function of load range based on API RP 2SK [13].
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It is considered that the outer strand outer wires have additionally been affected by the
onset of corrosion - the lubricant was generally missing or low/denatured. It is noted that
had the wire rope been assessed under the criteria of ISO 4309:2010 [5], then it would have
been subject to immediate discard.
In fact the condition of the wire rope is so poor as to raise the question of its condition when
last inspected in July 2016 [4]. It is noted that the wire rope was re-socketed in July 2016 -
given the condition of the bridle sample IWRC when terminated for break test, it might
prove informative to remove and examine the spelter socket on the wire rope.
Turning to consider the sorts of loads which the wire rope might have experienced during
the storm, an approximate calculation assuming a maximum wave height of 16.8 m indicates
a load of the order of 599 tonnes. This load is well in excess of the measured tug side sample
BL of 389 tonnes, and above the wire rope Fmin (485 tonnes) and the measured ABL of
494.1 tonnes. Given this estimate, it is not surprising the wire rope failed. It is quite possible
that the wire rope would have failed even if it had been as new.
It is noted that the load stated above assumes that the winch drum would not have slipped
or rendered. Details of the winch drum are not known, but a data sheet (Figure 17.2)
indicates that with 740 m paid out the brake holding load was about 1725 kN or 176 tonnes.
It has been reported that the winch had been rendering and loads of 180 - 220 tonnes had
been recorded [3]. It is possible that a shock load might be applied to the wire rope so
quickly that the drum did not have time to accelerate.
In addition to setting the winch to render, another option to help manage the loads on the
wire rope would be to extend the scope of the towing line. Whilst it is not ideal to drag a
wire rope along the seabed, in cases of extreme need it would be preferable to do this so as
to help avoid breaking the line.
In conclusion, this study has shown that the 77 mm wire rope installed on the ALP Forward
in May 2014 satisfied the requirements of API 9A [1]. Although the tow wire log [4] states
that the line is regularly washed and greased during recovery, it is far from clear that this
process is effective - the lubricant on the tug side and bridle samples were very low and the
wire rope has started to corrode. (Generally speaking it is preferable to avoid re-greasing a
wet wire rope as this can trap moisture in the wire rope accelerating corrosion. It is possible
that this has happened to the wire rope examined here.) The condition of the core was very
poor.
It is likely that the rope had become further degraded through fatigue damage during the
earlier part of the storm, and finally broke due to a one off overload.
Breaking load tests on sections of wire rope from either side of the main failure suggest that
at the time of the incident the wire rope strength was down by 21.3% to about 389 tonnes.
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Figure 17.2: ALP Forward main winch data sheet (supplied by MAIB).
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18 References
1 API 9A Specification for wire rope, 26th edition, May 2011, Reaffirmed April 2016,
published American Petroleum Institute.
2 Usha Martin Wire Rope Hand Book Published by Usha Martin (ushamartin.com) p75.
3 Pers. Comm. data supplied by MAIB (Capt. Emma Tiller) in .xls spread sheet 'Towline'.
4 ALP Maritime Services, Main tow-wire log .xls spread sheet forwarded by MAIB file
name 'Updated Tow Wire Record Alp Forward.xls'.
5 BS ISO 4309:2010 Cranes – wire ropes – care and maintenance, inspection and discard,
International Standards Organisation, 4th Edition, August 2010, ISBN: 978 0 580
59980 4.
6 BS EN 10264-2:2012 Steel wire and wire products – Steel wire for ropes Part 2: Cold
drawn non alloyed steel wire for ropes for general applications, British Standards
Institution, 2012.
7 ISO 10425:2003 Steel wire ropes for the petroleum and natural gas industries –
minimum requirements and terms of acceptance, International Standards
Organisation, August 2003.
8 ISO 7800:2012 Metallic materials – Wire – Simple torsion test, International Standards
Organisation, March 2012.
9 ISO 7801:1984 Metallic materials – Wire – Reverse bend test, International Standards
Organisation, May 1984.
10 BS EN 10244-1:2001 Steel wire and wire products – non-ferrous metallic coatings on
steel wire – Part 1: General principles, British Standards Institution, 2001.
11 Ractliffe, A.T. and Parsey, M.R. Man-made-fibre ropes for marine use, Trans North
East Coast Institution of Engineers and Shipbuilders (NECIES) 101 (1985) pp 183-
197.
12 Stretch, R. Met Office Marine Weather Data report compiled for MAIB Reference
msc/08/16/056, 30th August 2016, §7.2.
13 API RP 2SK Design and analysis of stationkeeping systems for floating structures, 3rd
edition October 2005, Addendum 2008, published American Petroleum Institute.
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Appendices
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Table E1: Description and short designation of the wire samples used in the results Tables.
In each case, the results of the tests on the wires have been compared to the original
measured value on the wire stock (where known) or in the absence of this information to
the minimum requirement specified by the appropriate standard. In order to aid a 'quick'
interpretation of the results, on the right hand side of each table is a column with coloured
cells. These cells are coloured as follows:
• green where the test result met or exceeded the original (or standard minimum)
value,
• orange if they were at or above 90% but below 100%; and,
• red if below 90%.
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